National Roads Authority. Manual of Contract Documents for Road Works (NRA MCDRW)

National Roads Authority Manual of Contract Documents for Road Works (NRA MCDRW) AMENDMENT No. 1 (December 2014) to NRA Specification for Road Works Series 900 Road Pavement Bituminous Bound Materials Dated March 2011 The NRA (NRA MCDRW), Series 900 Road Pavement Bituminous Bound Materials, dated March 2011 is amended as follows:- 1. Page 1, new Clause 900; Add text for new Clause 900 to the Contents as 900 NRA IAN 10/14. 2. Page 3, new Clause 900; Add text for new Clause 900 to include the following; 900 NRA IAN 10/14 It is intended that the requirements set out in NRA IAN 10/14 NRA entitled Specification for Road Works Series 900 Road Pavements Bituminous Materials will replace this specification by 15th April 2015. December 2014 i

ROAD PAVEMENTS BITUMINOUS BOUND MATERIALS Contents Clause Title Page 900 NRA IAN 10/14 1... 3 901 Bituminous Pavement Mixtures... 3 902 Reclaimed Asphalt... 4 903 Placing and Compaction of Bituminous Mixtures... 5 904 Not Used... 8 905 Not Used... 8 906 Dense Base and Binder Course Asphalt Concrete (Recipe Mixtures)... 9 907 Regulating Course... 10 908 Not Used... 10 909 Dense Asphalt Concrete Surface Course... 10 910 Hot Rolled Asphalt Surface Course (Recipe Mixtures)... 13 911 Hot Rolled Asphalt Surface Course (Design Mixtures)... 15 912 Close Graded Asphalt Concrete Surface Course... 16 913 Not Used... 18 914 Not Used... 18 915 Coated Chippings for Application to Hot Rolled Asphalt Surface Course... 18 916 Open Graded Asphalt Concrete Surface Course... 18 917 Cold-milling (Planing) of Bituminous Bound Flexible Pavement... 20 918 Slurry Sealing... 20 919 Surface Dressing: Recipe Specification... 22 920 Bond Coats, Tack Coats and other Bituminous Sprays... 23 921 Surface Macrotexture of Bituminous Surface Courses... 23 922 Not Used... 24 923 Binder Reclaimed using the Rapid Recovery Test (RRT) and Accelerated Ageing using the Modified Ageing Rolling Thin Film Oven Test (RTFOT)... 24 1 Amended as per Amendment No. 1, Item No. 1 March 2011 1

924 High Friction Surfacing... 29 925 Testing of Bituminous Mixtures... 30 926 Not Used... 30 927 Not Used... 30 928 Determination of the Complex Shear (Stiffness) Modulus (G*) and Phase Angle (δ) of Bituminous Binders using a Dynamic Shear Rheometer (DSR) Scope... 30 929 Dense Base and Binder Course Asphalt Concrete (Design Mixtures)... 34 930 EME2 Base and Binder Course Asphalt Concrete... 38 931 Not Used... 43 932 Not Used... 43 933 Not Used... 43 934 Not Used... 43 935 Not Used... 43 936 Not Used... 43 937 Stone Mastic Asphalt (SMA) Regulating Course... 43 938 Porous Asphalt... 47 939 Not Used... 52 940 Relative Hydraulic Conductivity Test... 52 941 Modified Binder Storage Stability Test... 54 942 Polymer Modified Stone Mastic Asphalt Surface Course... 56 943 Hot Rolled Asphalt Surface Course and Binder Course (Performance-Related Design Mixtures)... 60 944 Not Used... 61 945 Weather Conditions for Laying of Hot Bituminous Mixtures... 62 March 2011 2

900 NRA IAN 10/14 2 It is intended that the requirements set out in NRA IAN 10/14 entitled NRA Series 900 Road Pavements Bituminous Materials will replace this specification by 15th April 2015. 901 Bituminous Pavement Mixtures General 1 This clause gives general requirements for the properties of the aggregates and bitumen used in plant-produced bituminous mixtures. These requirements apply to all plant produced bituminous mixtures unless other requirements are given in specific Clauses in this Series. 2 Bituminous mixtures shall be produced in plants that are independently accredited to ISEN 9001 or equivalent quality management system. Products specified in accordance with IS EN 13108 shall be CE marked. All bituminous mixtures shall be laid by contractors operating in compliance with Series 700, relevant clauses of this series and BS594987. 3 Evaluation of conformity shall be carried out in accordance with the appropriate sections of IS EN 13108. Aggregates for Bituminous Mixtures 4 Aggregates shall be natural, clean, hard and durable crushed rock or crushed gravel and shall comply with the selected requirements of IS EN 13043. Crushed gravel shall comply with category C100/0 as defined in IS EN 13043. Additionally, aggregates for use in surface course mixes, surface dressing, and in coated chippings for application to rolled asphalt surface courses shall be of a single rock type and source. Where different PSV requirements demand different surface course mixes within the same scheme, the aggregates for each mix shall be selected to provide a similar colour throughout the area of surfacing within the contract. Where recycled coarse aggregate is used in bituminous mixtures, it shall have been tested and the content of other materials (Class X) including wood, plastic and metal shall not exceed 1% by mass. Reclaimed asphalt shall comply with Clause 902. Resistance to Fragmentation (Hardness) 5 Irrespective of source, coarse aggregates for bituminous mixtures shall be considered suitable if: (i) or (ii) the resistance to fragmentation category of the coarse aggregate as defined in clause 4.2.2 of EN 13043 shall be LA30 or less; crushed rock aggregate has a Los Angeles Value greater than 30 but less than 35, where evidence can be presented to the Employer s Representative of previous satisfactory use of the source in asphalt; and the material complies with any additional requirements in Appendix 7/1. Natural and manufactured (artificial) aggregates recovered from a previous use in an unbound form shall comply with the requirements of this Clause. Resistance to Freezing and Thawing (Durability) 6 When required in Appendix 1/5, the resistance of the coarse aggregate to freezing and thawing shall be tested. The freezing and thawing (soundness) category, as defined in IS EN 13043, clause 4.2.9.2, shall be MS25 unless otherwise specified in Appendix 7/1. The water absorption value of the coarse aggregate shall be determined in accordance with IS EN 13043, clause 4.2.9.1. If the water absorption value of the coarse aggregate is greater than WA242, the soundness test shall be carried out on the material delivered to Site. The requirements for water absorption do not apply to blast furnace slag aggregate. Cleanness 7 The proportion of coarse and fine aggregates for bituminous mixtures passing the 0,063mm test sieve (fines content) shall not exceed the limits 2 Amended as per Amendment No. 1, Item No. 2 March 2011 3

stated in the relevant target composition tables included within this Series, when tested in accordance with the washing and sieving method of IS EN 933-1. Resistance to Polishing and Surface Abrasion 8 When specified in the appropriate clause or Appendix 7/1, the aggregate shall conform to the required declared PSV category in accordance with IS EN 13043 clause 4.2.3 and the relevant section of SR17. 9 An aggregate shall be deemed acceptable if the mean of the two most recent consecutive PSV results from tests relating to the aggregate to be supplied complies with the declared categories specified in Appendix 7/1. The tests must be carried out within the previous 12 months by testing by an appropriate INAB or equivalent accredited organisation. 10 The resistance to surface abrasion of coarse aggregate used in surface courses in accordance with IS EN 13043 clause 4.2.4, and the relevant section of SR17 shall conform to category AAV10 or such other category as specified in the appropriate clause. Chemical Requirements Dicalcium Silicate Disintegration 11 Air-cooled blast furnace slag aggregates shall be free from iron dicalcium silicate disintegration as defined in IS EN 13043, clause 4.3.4.1. Iron Disintegration 12 Air-cooled blast furnace slag aggregates shall be free from iron disintegration as defined in IS EN 13043, clause 4.3.4.2. Volume Stability 13 The volume stability category of steel slag aggregates as defined in IS EN 13043, clause 4.3.4.3 shall not exceed V10. Bitumen 14 Paving grade bitumen shall comply with IS EN 12591 and/or IS EN 13924 as appropriate and supplied from locations that are independently accredited to ISO 9001 or equivalent quality management system with specific reference to the requirements of IS EN 13108-21. 15 Polymer modified bitumen shall comply with IS EN 14023 and shall only be used where specifically permitted within this 900 series and be supplied from locations that are independently accredited to ISO 9001 or equivalent quality management system with specific reference to the requirements of IS EN 13108-21. 902 Reclaimed Asphalt 1 Reclaimed bituminous materials may be used in the production of bituminous base and binder course, subject to the requirements of IS EN 13108-8 for foreign matter category F5. The maximum amount of reclaimed bituminous material permitted shall be 50% for Asphalt Concrete base and/or binder course. 2 After mixing with recycled materials, the binder reclaimed from the mixture shall have a recovered penetration value not less than the value specified in table 9/1. The binder shall be reclaimed from the mixture in accordance with the requirements of IS EN 12697 part 3 and tested in accordance with the requirements of IS EN 1426. Samples of the final plant mixed material must be taken at a frequency of once per thousand tonnes or a minimum of one per day. Table 9/1 Specified Grade of Binder to IS EN 12591 (Paving Grade) Minimum recovered penetration value of binder after mixing 40/60 30 70/100 40-60 160/220 80-120 3 When reclaimed bituminous materials are to be used in the mixture, the recovered penetration value of the binder in the reclaimed bituminous materials before mixing shall exceed 15 pen, after recovery of binder in accordance with the requirements of IS EN 12697 part 3 and testing in accordance with the requirements of IS EN 1426. 4 Where reclaimed asphalt is to be used in asphalt concrete mixtures the following requirements shall apply. All reclaimed bituminous materials shall be pre-treated before use such that the material is homogeneously mixed and the maximum particle size of reclaimed material does not exceed the upper size of the mixture or 0/32 whichever is the lesser. All reclaimed asphalt shall be classified in accordance with IS EN 13108-8. It is recommended that reclaimed asphalt comply with the following categories: Foreign matter Category F5. March 2011 4

The IS EN 13108-8 Category F5 can be used to define the reclaimed asphalt at any stage between the raw planed or excavated material and a fully processed feedstock for a mixing plant. In cases where reclaimed asphalt is added to the mixture, it is necessary to confirm that the properties of the total binder in the mixture, calculated from the combination of the properties of the fresh binder and the properties determined on the recovered binder from the reclaimed asphalt, conform to the grade specification for the mixture. IS EN 13108 gives the option of carrying out this calculation on either penetration or softening point. It is recommended that the penetration method is adopted in Ireland. For all additions of reclaimed mixture, the penetration of the recovered binder from the reclaimed material shall be no less than 15 mm at 25 o C, i.e. Category P15. 5 The use of reclaimed asphalt in surface courses shall not be allowed. 903 Placing and Compaction of Bituminous Mixtures General 1 This clause gives general requirements for placing and compaction of bituminous mixtures, which are complementary and additional to the requirements of BS 594987 and the Series 700. These requirements and the requirements of BS 594987 apply to all bituminous mixtures, unless otherwise specified in the other Clauses in this Series. Where there is conflict between this Clause, or other Clauses in this Series, and BS594987, this Clause, or other Clauses in this Series, shall take precedence over BS594987. 2 Bituminous pavements shall be constructed using the materials specified in Appendix 7/1. impracticable, by rectification in compliance with Series 700. 4 Prior to placing bituminous material on any new or existing bound substrate, a bond coat or tack coat shall be applied in accordance with Clauses 920 or 942, as appropriate. 5 Before work commences, the Contractor shall submit a method statement to the Employer s Representative that includes: (i) (ii) Laying and compaction procedures for each layer including paving speed and paved width; size, type and number of rollers; and number of roller passes. The joint formation procedures for each layer including the location of longitudinal and transverse joints; and the method(s) of treating upstanding edges. Temperature of the Mixture 6 When using paving grade binder, the maximum temperatures of the mixture, measured according to IS EN 12697-13, shall be within the general limits contained in Table 9/2 and the overriding limits contained in sub-clauses 937.17, 938.11 and 942.15 for specific mixtures and modified binders. The maximum temperature applies at any place in the plant. The minimum temperatures given here are for guidance only. 7 The minimum temperature at delivery (i.e. discharge into the truck at the plant) shall be declared by the manufacturer within the type test report. Suitable minimum temperatures at delivery to site and for compaction shall be in accordance with BS 594987. Transporting 8 Hot bituminous mixtures shall be transported in accordance with the requirements of BS 594987 and shall remain covered whilst awaiting tipping. 3 In order to exclude moisture from interfaces and ensure full interlayer bonding, the surface of all bituminous material shall be kept clean and uncontaminated. Unless agreed with the Employer, the only traffic permitted to run on the surface of bituminous material to be overlaid shall be that engaged in laying and compacting the next course or, where a binder course is to be blinded or surface dressed, that is engaged on such surface treatment. If any surface becomes contaminated, it shall be made good by cleaning and, if this proves March 2011 5

Table 9/2 Temperature limits of the mixture Paving grade of binder Temperature o C Recommended minimum discharge at plant Maximum 10/20, 15/25 160 200 40/60 150 190 70/100 140 180 160/220 130 170 Modified Binders See NOTE 1 See NOTE 1 Notes: 1 When using modified bitumen or additives, different temperatures may be applicable and advice should be sought on the mixing & handling temperatures from the binder manufacturer. These temperatures shall be documented and declared as part of the type testing report. 2 Producers should note that care should be taken to avoid damage to the mixture properties arising from excessive or prolonged heating. Layer Thickness 9 Nominal and minimum compacted layer thicknesses for asphalt concrete, hot rolled asphalt and stone mastic asphalt mixtures shall be in accordance with the relevant tables in BS. 594987 unless otherwise specified in Appendix 7/1. Laying 10 Hot bituminous mixtures, other than those specified under Clause 938 and 942, shall be laid in accordance with the requirements of BS 594987 and sub-clauses 10 to 16 of this Clause. Surfacings specified under Clause 938 and 942 shall be laid in accordance with the requirements of that Clause and sub-clauses 10 to 16 of this Clause. Hot bituminous mixtures shall only be laid in weather conditions complying with Clause 945. 11 Wherever practicable, hot bituminous mixtures shall be spread, levelled and tamped by a selfpropelled paving machine. The rate of delivery of material to the paver shall be regulated to enable the paver to operate continuously. 12 Hand placing of hot bituminous mixtures shall be restricted to the following circumstances: (i) For laying regulating courses of irregular shape and varying thickness. (ii) In confined spaces where it is impracticable for a paver to operate. (iii) (iv) (v) For footways. At the approaches to expansion joints at bridges, viaducts or other structures. For laying mastic asphalt. 13 Hand-raking of surface course material or the addition of such material by hand spreading to the paved area, for adjustment of level, shall be restricted to the following circumstances: (i) (ii) At the edges of the layers of material and at gullies, manholes and other ironwork. At the approaches to expansion joints at bridges, viaducts or other structures. (iii) In confined spaces where it is impracticable for a paver to operate. 14 The method of laying shall be such that the finished mat is free from dragging, tearing and segregation of the material. 15 When laying mixtures from more than one source, the mixtures shall have equivalent laying and compaction characteristics so that surface evenness is not compromised. 16 When paving adjacent to an expansion joint of a structure, the joint or joint cavity shall be kept clear of material. When laying binder course or surface course, the paver shall be taken out of use whilst laying the remainder of March 2011 6

the pavement up to the joint and the corresponding area beyond it. 17 When paving directly onto bridge deck waterproofing systems, any special requirements which apply to that system shall be complied with. Compaction 18 The compaction and compaction control of hot bituminous mixtures shall be in accordance with BS 594987 and the requirements for specific mixtures in: (i) (ii) (iii) (iv) Clause 906 for Dense Base and Binder Course Asphalt Concrete (Recipe Mixtures) Clause 929 for Dense Base and Binder Course Asphalt Concrete (Design Mixtures). Clause 930 EME2 Base and Binder Course Asphalt Concrete Clause 937 Stone Mastic Asphalt (SMA) Binder Course and Regulating Course 22 Where core specimens are required for the determination of properties of the laid and compacted materials, they shall be cut in accordance with BS EN 12697-27, from locations to be representative of the area or material under investigation. Cores shall be extracted without the use of excessive force and without causing damage to the core. Cores shall not be taken from freshly laid asphalt until it has cooled to a temperature of 40 C or less at mid-depth of the course to be cored. Chippings 23 The application of coated chippings to areas of surface course shall be by a mechanical spreader capable of distributing chippings to an even rate of spread. Addition of chippings by hand operation shall only be permitted in the following circumstances: (i) In confined spaces, where it is impracticable for a chipping spreader to operate. (ii) As a temporary expedient, when adjustments have to be made to the spreader distribution mechanism. (v) Clause 938 Porous Asphalt Surface Course (iii) When hand laying of the surface course is permitted. (vi) Clause 943 Hot Rolled Asphalt Surface Course and Binder Course (Performance- Related Design Mixtures) Materials covered by clauses 910, 911, 912 and 916 will rely upon method specifications in accordance with BS594987 for compaction control. 19 Except where otherwise specified, rollers shall comply with the general requirements of BS 594987 except that the minimum mass of deadweight smooth wheeled rollers shall be 8 tonnes. Multi-wheeled pneumatic-tyred rollers and vibratory rollers may be used if they are capable of achieving at least the standard of compaction of an 8-tonnes deadweight roller. 20 Where compaction is to be determined in accordance with Clauses 929 and 930 the requirements to prove the performance of rollers do not apply. In such cases, the Contractor may use any plant to achieve the specified level of compaction and shall finish compaction at temperatures above the minimum specified rolling temperature. 21 Vibratory rollers shall not be used in vibrating mode on bridge decks. (iv) To correct uneven distribution of chippings. 24 Chippings shall be applied uniformly and rolled into the surface so they are effectively held and provide the initial macrotexture depth specified in Clause 921. Joints 25 Unless agreed otherwise with both the Employer s Representative and Specialist responsible for the design, longitudinal joints in all layers shall be situated outside wheel-track zones. For the purposes of this Clause, the wheel-track zones shall be taken to be between 0,4m and 1,0m and between 2,45m and 3,05m from the centre of the nearside lane markings for each traffic lane (or, in the absence of lane markings, lane edges). All joints shall be offset at least 150mm from parallel joints in the layer beneath. Joints in the surface course shall coincide with either the lane edge or the lane marking, whichever is appropriate. 26 The faces of all cold upstanding edges, including previously laid asphalt, against which hot bituminous mixtures are to be laid to form joints shall be treated with one of the following: March 2011 7

(i) hot bituminous binder with a penetration of not less than 40 pen. (ii) hot elastomeric polymer-modified bituminous binder complying with IS EN 14023 with a penetration of not less than 40 pen. (iii) cold applied thixotropic bituminous compound of similar bitumen or polymermodified bitumen grade. (iv) polymer-modified adhesive bitumen strip with a minimum thickness of 2mm. This operation shall be done so that the binder adheres to both the cold and the warm upstanding edges when the asphalt is placed. 27 Joints in regulating and binder courses that are less than 50mm thick shall be treated as specified in BS 594987 for surface courses. 28 Joints in binder courses and bases shall be compacted such that the air voids content measured from core pairs whose centres are not more than 100mm from the final joint is not greater than 2% above the maximum permitted limit for core pairs in the body of the mat. The air voids content shall be calculated in accordance with IS EN 12697-8 using the relevant bulk and maximum densities defined in Appendix B of IS EN 13108-20 for the relevant mixture type. 29 Within 24 hours of the joint being formed, a sealant shall be applied to the top surface of all base and binder course joints such that there is not less than 0,50kg/m² of residual bitumen 75mm either side of the joint. The sealant, which may contain mineral filler to IS EN 13043, shall be one of the following: (i) hot elastomeric polymer-modified bituminous binder complying with IS EN 14023 with a penetration of not less than 40 pen. (ii) bitumen emulsion with a cohesion by pendulum of Class 4 or above in accordance with IS EN 13808. Regulating Course 31 Regulating course material shall be made and laid in accordance with the requirements of Clause 907. Use of Surfaces by Traffic 32 If due to unforeseen circumstances, a base or binder course material must unavoidably be left unsurfaced over a period of time, during which construction activity is not ongoing at the site, the local authority should implement appropriate measures to ensure that drivers are adequately alerted to the unfinished nature of the surface. These measures should include: Appropriate signage and lining in accordance with Chapter 8 of the Traffic Signs Manual DOT, The use of Cautionary Speed Plates or Statutory Road Works Speed Limits as appropriate. In addition, in such circumstances distinctive orange coloured road marking tape or paint should be used as temporary centre line and edge markings to further emphasise the unfinished nature of the road. The measures outlined should remain in place until the final surface course is laid. 33 Construction plant used on pavements under construction shall be suitable in relation to the material, condition and thickness of the courses it traverses so that damage is not caused to the subgrade or the pavement courses already constructed. The wheels or tracks of plant moving over the various pavement courses shall be kept free from deleterious materials. Trafficking Newly Laid Surfacing 34 The Contractor shall ensure the pavement material has adequately cooled and hardened before the road is opened to traffic. Unless otherwise agreed by the Employer s Representative, the road shall not be opened to traffic if its surface temperature exceeds 25 C unless the maximum temperature within the mat has fallen below 35 C. (iii) slurry surfacing complying with Clause 918. 904 Not Used 30 A sealant, as specified in sub-clause 29 of this Clause, shall be applied to the whole of any freestanding edge on the outside of the finished pavement on the high side of the camber and, when specified in Appendix 7/1, on the low side. 905 Not Used March 2011 8

906 Dense Base and Binder Course Asphalt Concrete (Recipe Mixtures) 1 Dense base and binder course asphalt concrete recipe mixtures shall be asphalt concrete conforming to IS EN 13108-1, the requirements specified in this Clause and Appendix 7/1. The mixture designation shall be one of the following: (i) AC 32 dense base 40/60 rec (ii) AC 32 dense base 70/100 rec (iii) AC 32 dense bin (iv) AC 32 dense bin 40/60 rec 70/100 rec (v) AC 20 dense bin 40/60 rec (vi) AC 20 dense bin (vii) AC 32 HDM bin (viii) AC 32 HDM base (ix) AC 20 HDM bin 70/100 rec 40/60 rec 40/60 rec 40/60 rec 2 When the mixture designation is not specified in Appendix 7/1, the mixture selected by the Contractor shall be notified to the Employer s Representative prior to its use in the Works. Composition 3 Evaluation of conformity shall be carried out in accordance with IS EN 13108-1 which requires specifications to be presented as a grading envelope within which the producer's declared target grading must fall. The grading specification in Table 9/3 gives single point and/or very narrow envelope gradings, which, in combination with the tolerances from IS EN 13108-21 result in overall grading envelopes similar to those previously specified in BS 4987. 4 For base and binder course mixtures, the target and/or minimum binder content is defined in Table 9/3. 5 The aggregate grading of the target composition shall fall within the envelope given in Table 9/3. Aggregate 6 The coarse aggregate shall consist of crushed rock complying with Clause 901.4. 7 The fine aggregate shall comply with the requirements of IS EN 13043. 8 The fine aggregate shall be either a 0/2 mm or a 0/4 mm aggregate fraction and be of one of the following types: (a) crushed rock fines produced from coarse aggregate defined in IS EN 13043 or (b) sand; or (c) a mixture of a) and b). 9 If added filler is used in dense mixtures it shall consist of crushed rock, crushed slag, hydrated lime, cement (CEM I or CEM II complying with IS EN 197-1). 10 All aggregate shall be in a surface dry condition prior to mixing. Binder 11 The binder shall be petroleum bitumen of paving grade 40/60 or 70/100 Pen complying with IS EN 12591 as described in Appendix 7/1. Compaction Control Procedures 12 The compaction level of base and binder course macadams shall be continuously assessed using an indirect density gauge in accordance with BS 594987 Clause 9.4.2 with readings taken at 20m intervals in alternate wheel tracks. Gauge readings shall also be taken at each core location specified in sub clauses 16 and 18. Each gauge shall be individually calibrated on each mixture from each mixing plant and the calibrations shall be continually checked and updated based on correlations between gauge readings and core densities at the same locations. 13 For each location, the in situ void content shall be determined in accordance with IS EN 12697-8 using the bulk density from the gauge reading and a maximum density taken from the mixture type testing data and updated with values from testing in accordance with sub- Clause 15. 14 The average in situ void content calculated from any six consecutive indirect gauge readings shall not exceed 7%. 15 In the event of a failure to meet the requirements in sub-clause 14, cores shall be taken at each location and void contents determined as described in sub-clause 20 and the evaluation of the extent of any non conformity shall be based on these. In the event of dispute or discrepancy between the two methods, only results obtained from the cores will be considered for compliance purposes. If it is necessary to remove and replace any material to restore conformity this shall be in lengths not less than 15m unless otherwise agreed by the Employer. March 2011 9

16 For the material from each mixing plant, a pair of cores shall be taken from the wheel tracks every 1000 metres laid and the void content shall be determined in accordance with BS 594987, such that for each of the cores, the in situ void content shall be determined in accordance with IS EN 12697-8, using the bulk density in accordance with IS EN 12697-6:2003, procedure B, saturated surface dry condition and the mean maximum density from the broken down core determined in accordance with IS EN 12697-5:2002, procedure A, in water. 17 The average in situ air voids for each core pair shall not exceed Vmax7. 18 For the material from each mixing plant a pair of cores shall be taken every 250 metres laid, centred 100mm from the final joint position at any unsupported edge and the air void shall be determined in accordance with BS 594987, such that for each of the cores, the in situ void content shall be determined in accordance with IS EN 12697-8, using the bulk density in accordance with IS EN 12697-6:2003, procedure B, saturated surface dry condition and the mean maximum density from the broken down core determined in accordance with IS EN 12697-5:2002, procedure A, in water. 19 The average in situ void content for each of these pairs shall not exceed Vmax9. 20 In the event of non conformity with sub-clauses 17 or 19 then density readings with indirect gauges and, if necessary, further cores shall be taken to establish the extent. In the event of dispute or discrepancy between the two methods, only results obtained from the cores will be considered for compliance purposes. If it is necessary to remove and replace any material to restore conformity, this shall be in lengths not less than 15m unless otherwise agreed by the Employer. 21 Each core extracted shall be examined for evidence of excessive voids below the depth to which the indirect density gauge penetrates. If excessive voids are observed, further cores shall be taken to determine its extent. 22 Two copies of the final indirect density test results obtained and their correlation with in situ air void contents shall be passed to the Employer s Representative within 72 hours. 907 Regulating Course 1 Regulating courses, which may consist of one or more layers of a bituminous material, shall have their finished surfaces laid to achieve the appropriate tolerances for horizontal alignments, surface levels and surface regularity for pavement layers, in accordance with Series 700. Adopted material shall be appropriate for the layer thickness as defined in BS594987. 2 Unless otherwise specified in Appendix 7/1, Stone Mastic Asphalt complying with Clause 937, Base or Binder course asphalt concrete complying with Clause 906 or Hot Rolled Asphalt complying with Clause 910, shall be used for regulating courses immediately below surface courses. Bituminous mixtures for regulating courses shall meet the requirements for the appropriate material, as specified above. 3 Where the total depth of a regulating course exceeds 100mm then the course shall be laid so that each regulating layer has a compacted thickness of between 50mm and 100mm. 908 Not Used 909 Dense Asphalt Concrete Surface Course 1 Dense Asphalt Concrete surface course shall be asphalt concrete conforming to IS EN 13108-1, the requirements specified in this Clause and Appendix 7/1. The mixture designation shall be one of the following: (i) AC 6 Dense Surf 70/100 rec (ii) AC 6 Dense Surf 160/220 rec 2 When the mixture designation is not specified in Appendix 7/1, the mixture selected by the Contractor shall be notified to the Employer s Representative prior to its use in the Works. 3 Evaluation of conformity shall be carried out in accordance with IS EN 13108-1. Additives 4 Additives permitted for inclusion may include: fibres, pigments and adhesion agents. The suitability of such additives shall be demonstrated in accordance with clause 901.2 and IS EN 13108-4. March 2011 10

Composition 5 Evaluation of conformity shall be carried out in accordance with IS EN 13108-1 which requires specifications to be presented as a grading envelope within which the producer's declared target grading must fall. The grading specification in Table 9/4 gives single point and/or very narrow envelope gradings, which, in combination with the tolerances from IS EN 13108-21 result in overall grading envelopes similar to those previously specified in BS 4987. 6 For surface course mixtures, the target and/or minimum binder content is defined in Table 9/4. 7 The aggregate grading of the target composition shall fall within the envelope given in Table 9/4. March 2011 11

Table 9/3 Target limits for composition of AC 32 Base and Binder Course and AC 20 Binder Course recipe mixtures Recipe Mixtures Previous BS nomenclature: 32 mm base 32 mm binder course 20 mm binder course New EN nomenclature: AC 32 DBM/HDM a base AC 32 DBM/HDM a bin AC 20 DBM/ HDM a bin Test sieve aperture size (mm) % by mass Passing % by mass passing % by mass passing 40 100 100-31,5 99 100 99-100 100 20 80 86 80 86 99 100 14 - - - 10 - - 61 63 6,3 52 b,c 52 b,c 47 b,c 2 27 33 27 33 27 33 0,250 11 15 11 15 11 15 0,063 DBM & HMB 6 b 6 b 6 b 0,063 HDM 9 b 9 b 9 b Binder content Bact Aggregate type Target Target Target Limestone 4,0 4,7 4,7 Other crushed rock 4,0 4,7 4,7 Gravel 4,5 5,0 5,0 a Delete as appropriate b Single values are recommended to ensure consistency between the original BS 4987 mixtures and those derived from the European Standard. c There is no requirement in IS EN 13108-21 to apply a conformity tolerance to an optional extra coarse or fine aggregate sieve. However, to monitor mixture consistency it may be appropriate for the producer to apply the same tolerance as that applied to the characteristic coarse or fine sieve. NOTE For Design mixtures Bact is the minimum target binder content. March 2011 12

Table 9/4 Target limits for composition for AC 6 Surface Course Mixtures Previous BS nomenclature: New EN nomenclature: Test sieve aperture size (mm) Recipe Mixtures 6 mm dense surface course AC 6 dense surf % by mass passing 10 100 6,3 98 a 4-2 42 56 1 24 46 0,250 11 19 0,063 4 8 Aggregate type Binder content Bact Target Limestone 6,0 Other crushed rock 6,3 Gravel a Single values are recommended to ensure consistency between the original BS 4987 mixtures and those derived from the European Standard. b The information on the target bitumen contents required for these mixtures made with gravel is not sufficient for a single target value to be specified. The bitumen content to be used should be chosen within the range 5,4 % to 6,6 %. Aggregate 8 The coarse aggregate shall consist of crushed rock complying with Clause 901.4. b 9 The fine aggregate shall comply with the requirements of IS EN 13043 10 The fine aggregate shall be either a 0/2 mm or a 0/4 mm aggregate fraction and be of one of the following types: a) crushed rock fines produced from coarse aggregate defined in IS EN 13043 or b) sand; or c) a mixture of a) and b). 11 If added filler is used in dense mixtures it shall consist of crushed rock, crushed slag, hydrated lime, cement (CEM I or CEM II complying with IS EN 197-1). 12 All aggregate shall be in a surface dry condition prior to mixing. Binder 13 The binder shall be petroleum bitumen of paving grade 70/100 or 160/220 Pen complying with IS EN 12591 as described in Appendix 7/1. 910 Hot Rolled Asphalt Surface Course (Recipe Mixtures) 1 Hot Rolled Asphalt surface course recipe mixes shall conform to IS EN 13108-4, and the requirements specified in Appendix 7/1. The mixture designation shall be one of the following, unless a stiffer binder is required by Appendix 7/1: (i) HRA 0/2 F surf 40/60 (ii) HRA 30/14 F surf 40/60 (iii) HRA 35/14 F surf 40/60 2 When the mixture designation is not specified in Appendix 7/1, the mixture selected by the Contractor shall be notified to the Employer s Representative prior to its use in the Works. 3 The binder shall be petroleum bitumen of paving grade 40/60 Pen complying with IS EN 12591 as described in Appendix 7/1. 4 Evaluation of conformity shall be carried out in accordance with IS EN 13108-4 which requires specifications to be presented as a grading envelope within which the producer's declared target grading must fall. The grading specification in Table 9/6 gives single point and/or very narrow envelope gradings, which must be used in combination with the tolerances from IS EN 13108-21 resulting in overall conformity grading envelopes. March 2011 13

Coarse Aggregate 5 The resistance to polishing of the coarse aggregate for chipped mixtures shall be category PSV44 as defined in IS EN 13043, clause 4.2.3. Fine Aggregate 6 The fine aggregate shall be either a 0/2 mm or a 0/4 mm aggregate fraction and be of one of the following types: (a) (b) (c) Added Filler sand; or crushed rock fines produced from coarse aggregate; or a mixture of a) and b). 7 Added filler shall consist of crushed rock, crushed slag, hydrated lime, cement (CEM I or CEM II complying with IS EN 197-1) or other material approved by both the Employer s Representative and the Specialist responsible for the design. 8 The loose bulk density in kerosene of added filler, with the exception of hydrated lime, shall be in accordance with clause 5.5.5 of IS EN 13043. Additives 9 Additives permitted for inclusion may include: fibres, pigments and adhesion agents. The suitability of such additives shall be demonstrated in accordance with clause 901.2 and IS EN 13108-4. Composition 10 For surface course mixtures, the target and/or minimum binder content is defined in Table 9/5. The binder content shall be: schedule 1A or 1B for crushed rock mixtures; schedule 2A or 2B for gravel mixtures. Schedule 1B 8,2 7,8 Schedule 2A 7,4 7,0 Schedule 2B 8,0 7,4 Table 9/6 Target Composition Limits for Type F Recipe Mixtures Target Aggregate Gradings D 0/2F 30/14F 35/14F Sieve Passing sieve % by mass 20-100 100 14-93-100 95-100 10-67-83 62-81 6,3 100 - - 2 98-100 65 61 0,5 80-90 49-68 44-63 0,25 40-65 19-51 16-46 0,063 14,0 9,0 8,0 Notes: 1 For additional grading requirements, for maximum percentage of aggregate passing 2 mm and retained on 0.5 mm sieves in surface course mixtures, refer to Table 5, IS EN 13108-4. 2 In practice, the maximum passing the 0.5 mm sieve will be restricted by the value passing the 2 mm sieve. 11 The aggregate grading of the target composition shall fall within the envelope given in Table 9/6. Coated Chippings 12 When required, coated chippings shall be 14/20mm and comply with Clause 915. Table 9/5 Type F Recipe Mixtures Target Binder Content Bact 30/14F 35/14F Schedule 1A 7,7 7,4 March 2011 14

911 Hot Rolled Asphalt Surface Course (Design Mixtures) 1 Hot Rolled Asphalt surface course design mixes shall conform to IS EN 13108-4 and the requirements specified in Appendix 7/1. The mixture designation shall be one of the following: (i) HRA 35/14 F surf 40/60 des (ii) HRA 30/14 F surf 40/60 des (iii) HRA 30/14 C surf 40/60 des (iv) HRA 35/14 C surf 40/60 des 2 The grade of bitumen required shall be 40/60 conforming to IS EN 12591 unless a stiffer binder is required by Appendix 7/1. 3 When the mixture designation is not specified in Appendix 7/1, the mixture selected by the Contractor shall be notified to the Employer s Representative prior to its use in the Works. 4 Evaluation of conformity shall be carried out in accordance with IS EN 13108-4. Layer Thickness 5 The nominal thickness of the Hot Rolled Asphalt surface course layer shall be in accordance with the relevant table of BS594987 unless otherwise specified in Appendix 7/1. Coarse Aggregate 6 The resistance to polishing of the coarse aggregate for chipped mixtures shall be category PSV44 as defined in IS EN 13043, clause 4.2.3. Additives 9 Additives permitted for inclusion may include: fibres, pigments and adhesion agents. The suitability of such additives shall be demonstrated in accordance with clause 5.2.5 of IS EN 13108-4. 10 The loose bulk density in kerosene of added filler, with the exception of hydrated lime, shall be in accordance with clause 5.5.5 of IS EN 13043. Composition 11 For Type F Design surface course mixtures, the target and/or minimum binder content shall not be less than either the appropriate minimum value from Table 9/7 and/or the design binder content determined in accordance with the protocol described in Annex H, BS 594987. 12 For Type F Design surface course mixtures, the aggregate grading of the target composition shall fall within the envelope given in Table 9/7 13 For Type C Design surface course mixtures, the target and/or minimum binder content shall not be less than either the appropriate minimum value from Table 9/8 or the design binder content determined in accordance with the protocol described in Annex H, BS 594987. 14 For Type C Design surface course mixtures, the aggregate grading of the target composition shall fall within the envelope given in Table 9/8. Coated Chippings 15 When required, coated chippings shall be 14/20mm. Coated chippings shall also comply with Clause 915. Fine Aggregate 7 The fine aggregate shall be either a 0/2 mm or a 0/4 mm aggregate fraction and be of one of the following types: (a) (b) (c) sand; or crushed rock fines produced from coarse aggregate; or a mixture of a) and b). Added Filler 8 Added filler shall consist of crushed rock, crushed slag, hydrated lime, cement (CEM I or CEM II complying with IS EN 197-1) or other material approved by the Employer s Representative and the Specialist responsible for the design. March 2011 15

Table 9/7 Limits for Target Composition for Type F Mixtures Design Target Aggregate Gradings D 30/14F 35/14F Table 9/8 Type C Design Mixtures - Target Aggregate Gradings and Binder Content D 30/14C 35/14C Sieve Passing sieve % by mass Sieve Passing sieve % by mass 20 100 100 20 100 100 14 93-100 95-100 10 67-83 62-81 6,3 - - 2 65 61 0,5 49-68 44-63 0,25 19-51 16-46 0,063 9,0 8,0 Minimum target binder content Bact Note: 6,5 6,4 1 For additional grading requirements, for maximum percentage of aggregate passing 2 mm and retained on 0,5 mm sieves in surface course mixtures, refer to Table 5, IS EN 13108-4. 2 In practice, the maximum passing the 0,5mm sieve will be restricted by the value passing the 2mm sieve. 14 93-100 95-100 10 67-83 62-81 6,3 - - 2 66 59 0,5 29-41 24-41 0,25 19-36 16-26 0,063 9,0 8,0 Minimum target binder content Bact 6,5 6,4 912 Close Graded Asphalt Concrete Surface Course 1 Close graded Asphalt Concrete surface course shall comply with this Clause, and the requirements specified in Appendix 7/1. The mixture designation shall be one of the following: (i) AC 10 Close Surf 160/220 rec (ii) AC 14 Close Surf 70/100 rec (iii) AC 14 Close Surf 160/220 rec (iv) AC 10 Close Surf 70/100 rec 2 When the mixture designation is not specified in Appendix 7/1, the mixture selected by the Contractor shall be notified to the Employer s Representative prior to its use in the Works. 3 Evaluation of conformity shall be carried out in accordance with IS EN 13108- March 2011 16

Table 9/9 Target limits for composition for AC 14 and AC 10 Close Graded Surface Course recipe mixtures Recipe Mixtures Previous BS nomenclature: New EN nomenclature: 14 mm close graded surface course AC 14 close surf 10 mm close graded surface course AC 10 close surf Test sieve % by mass passing % by mass passing aperture size (mm) 20 100-14 100 a 100 10 77 83 100 a 6,3 52 58 62 68 2 25 31 25 31 1 14 26 14 26 0,063 6 a 6 a Binder content Bact Aggregate type Target Target Limestone 4,9 5,2 Other crushed rock 5,1 5,3 Gravel b b a Single values are recommended to ensure consistency between the original BS 4987 mixtures and those derived from the European Standard. b The information on the target bitumen contents required for these mixtures made with gravel is not sufficient for a single target value to be specified. The bitumen content to be used should be chosen within the range 5,4 % to 6,6 %. Composition 4 Evaluation of conformity shall be carried out in accordance with IS EN 13108-1 which requires specifications to be presented as a grading envelope within which the producer's declared target grading must fall. The grading specification in Table 9/9 gives single point and/or very narrow envelope gradings, which, in combination with the tolerances from IS EN 13108-21 result in overall grading envelopes similar to those previously specified in BS 4987. 5 For surface course mixtures, the target and/or minimum binder content is defined in Table 9/9. 6 The aggregate grading of the target composition shall fall within the envelope given in Table 9/9. Aggregate 7 The coarse aggregate shall consist of crushed rock complying with Clause 901.4. 8 The coarse aggregate shall have a minimum resistance to polishing of PSV 55declared in accordance with IS EN 13043 Clause 4.2.3 unless a higher PSV category is required by Appendix 7/1. In addition, the resistance to abrasion of the coarse aggregate shall have a maximum category of AAV10 in accordance with IS EN 13043 Clause 4.2.4. 9 The fine aggregate shall be either a 0/2 mm or a 0/4 mm aggregate fraction and be of one of the following types: (a) crushed rock fines produced from coarse aggregate defined in IS EN 13043 or March 2011 17

(b) (c) sand; or a mixture of a) and b). 10 If added filler is used in close graded mixtures it shall consist of crushed rock, crushed slag, hydrated lime, cement (CEM I or CEM II complying with IS EN 197-1). 11 All aggregate shall be in a surface dry condition prior to mixing. Binder 12 The binder shall be petroleum bitumen of paving grade 70/100 or 160/220 Pen complying with IS EN 12591, as described in Appendix 7/1. 913 Not Used 914 Not Used 915 Coated Chippings for Application to Hot Rolled Asphalt Surface Course 1 The chippings and the manner of coating, when used for rolling into the surface of rolled asphalt, shall be in accordance with IS EN 13108-4, the following sub clauses and with sub-clause 901.4. 2 The resistance to polishing of the chippings shall be a minimum category PSV 55 declared, in accordance with IS EN 13043 Clause 4.2.3 unless a higher PSV category is required by Appendix 7/1. In addition, the resistance to abrasion of the coarse aggregate shall have a maximum category of AAV10 in accordance with IS EN 13043 Clause 4.2.4. The shape of the chippings shall comply with FI15 as defined in IS EN 13043 Clause 4.1.6. 3 The polished stone value shall be determined in accordance with IS EN 1097-8. The aggregate shall be deemed to comply if the 2 most recent consecutive results, from tests relating to the material to be supplied, and carried out within the previous 12 months by a testing laboratory accredited to ISO 17025 (INAB) approved by the Employer's Representative, are equal to or greater than that required by Appendix 7/1. 4 Binder used to coat the chippings shall be 40/60 grade conforming to IS EN 12591. The target binder content shall be not less than 1,5 %. On analysis, the binder content shall be within the range 1,2 % to 1,8 %. 5 When tested in accordance with IS EN 12697-37, the proportion of retained sand shall be not less than 4,0 % for D 16 mm and 5,0 % for D < 16 mm. Not more than 7,5 % shall fail the visual assessment. 6 Evaluation of conformity shall be carried out in accordance with IS EN 13043 and SR17. Table 9/10 Compliance grading of chippings Test sieve Mm 31,5 100 % (m/m) passing test sieve 14/20 size 20 90 100 14 0 25 10 0 4 6,3 0,063 0 2 916 Open Graded Asphalt Concrete Surface Course 1 Open graded asphalt concrete surface course recipe mixes shall be asphalt concrete conforming to IS EN 13108-1, the requirements of this Clause and the requirements specified in Appendix 7/1. The mixture designation shall be one of the following: (i) AC 10 open Surf 160/220 (ii) AC 10 open Surf 70/100 (iii) AC 14 open Surf 160/220 (iv) AC 14 open Surf 70/100 2 When the mixture designation is not specified in Appendix 7/1, the mixture selected by the Contractor shall be notified to the Employer s Representative prior to its use in the Works. 3 Evaluation of conformity shall be carried out in accordance with IS EN 13108-1. March 2011 18

Table 9/11 Target limits for composition for AC 14 and AC 10 Open Surface Course recipe mixtures Previous BS nomenclature: Recipe Mixtures New EN nomenclature: 14 mm open graded surface course AC 14 open surf 10 mm open graded surface course AC 10 open surf Test sieve aperture size (mm) % by mass passing % by mass passing 20 100-14 98 100 100 10 62-68 93 95 6,3 32 38 37 53 2 16 17 16 17 1 - - 0,063 5 a 5 a Binder content Bact Aggregate type Target Target Limestone 4,6 5,1 Other crushed rock 4,8 5,3 Gravel b b a Single values are recommended to ensure consistency between the original BS 4987 mixtures and those derived from the European Standard. b The information on the target bitumen contents required for these mixtures made with gravel is not sufficient for a single target value to be specified. The bitumen content to be used should be chosen within the range 5,4 % to 6,6 %. Composition 4 Evaluation of conformity shall be carried out in accordance with IS EN 13108-1 which requires specifications to be presented as a grading envelope within which the producer's declared target grading must fall. The grading specification in Table 9/11 gives single point and/or very narrow envelope gradings, which, in combination with the tolerances from IS EN 13108-21 result in overall grading envelopes similar to those previously specified in BS 4987. 5 For surface course mixtures, the target and/or minimum binder content is defined in Table 9/11. 6 The aggregate grading of the target composition shall fall within the envelope given in Table 9/11. Aggregate 7 The coarse aggregate shall consist of crushed rock complying with Clause 901.4. 8 To ensure adequate resistance to polishing and abrasion, the coarse aggregate shall have a minimum declared PSV and a maximum AAV, as specified in Appendix 7/1. 9 The fine aggregate shall be either a 0/2 mm or a 0/4 mm aggregate fraction and be of one of the following types: March 2011 19